Hyundai Transys and BASF have jointly introduced a next-generation modular seat concept for purpose-built vehicles (PBVs), featuring headrest and armrest components made for the first time with BASF’s Elastollan® thermoplastic polyurethane (TPU) using Supercritical Fluid (SCF) injection foaming technology. The innovation highlights how advanced sustainable materials can unlock new possibilities for automotive interior design.

“Through this partnership with Hyundai Transys, we’re demonstrating how material science and forward-thinking design can transform the future of mobility,” said Andy Postlethwaite, Senior Vice President, Performance Materials Asia Pacific. “Elastollan TPU is fully recyclable, and when processed with SCF injection foaming, it becomes a highly efficient and environmentally responsible solution for lightweight automotive components.”

Originally applied in the footwear industry, this cutting-edge TPU foam technology is now entering the automotive sector. The material enables soft-touch, abrasion-resistant, and premium-quality interior parts, while the SCF process ensures uniform gas dispersion. This results in a fine-cell foam structure with improved durability, reduced density, and significantly lower volatile organic compound (VOC) emissions—key advantages for manufacturers seeking low-VOC automotive interior materials.

The foaming process eliminates the need for crosslinking or chemical blowing agents, allowing components to be easily disassembled and recycled after use. This aligns with the EU’s proposed End-of-Life Vehicle Regulation (ELVR), which encourages circular design and recyclability in future vehicle development. With lower energy demand during production, the solution helps OEMs achieve carbon-neutral manufacturing goals while improving cost efficiency across the product lifecycle, including cost-to-own (CTO) benefits at end-of-life disposal.

By integrating Elastollan TPU with SCF injection foaming, Hyundai Transys and BASF are setting a new benchmark for customizable, sustainable, and modular seating systems in next-generation purpose-built vehicles.